How Laser Cut Metal Works: Guide to Lasers, Metals & Applications

Laser cutting is a new way to cut metal that has completely changed how the industry runs today. It is fast, perfect, and it lets people make all sorts of cool creations. The laser can cut things with amazing accuracy a whole lot better and easier than old-fashioned tools. The best part is that this technology makes professional-looking results possible for everyone, such as creators, hobbyists, and people with small businesses, without draining the bank account.

How Does Metal Laser Cutting Work?

Metal laser cutting works by using light instead of a physical blade to cut materials. The process begins by pointing a very strong, focused beam of light at the metal. This light heats the metal so fast that it actually melts or even turns into a gas, creating a cutting path with perfect accuracy. Since the laser never actually touches the material, the machine parts last much longer than if there was physical contact, such as what is the case with a blade. What is more, there are fewer mistakes on the metal, and there is not much mess to clean up afterward.

Because it is so accurate, this cutting method is the best choice for tiny details, complicated designs, and parts that need to fit together perfectly. The finished pieces always have smooth edges and are highly accurate, making this technology a favorite for creating everything from factory parts to beautiful decorations.

What Kind of Laser Can Cut Metal?

CO₂ lasers and fiber lasers are the two types typically used to cut metal. Both of these tools can cut materials well. However, they use different methods and are best for completing different jobs.

CO₂ lasers make their beam of light by using a mixture of carbon dioxide and other gases. They are amazing at cutting materials that are not metal, such as wood, leather, and plastic. When such tools do cut metal, they work best on thinner sheets. Trying to cut very thick sheets of metal with a CO₂ laser is much harder. This slows down the job and ends up using more electrical energy, which costs more money in the long run.

Fiber lasers work differently by making light through special cables called fiber optics. A system that uses fiber optics is better at delivering the powerful laser beam. Fiber lasers are generally faster, they use less energy, and they are much better at cutting shiny metals, such as copper or brass. If you compare two lasers with the same power, the fiber laser will almost always be faster and more accurate than the CO₂ system. Because of these advantages, fiber lasers are usually the best choice for modern metal cutting and fabrication.

If you would like to discover more about the differences of fiber laser and CO2 lasers, check this article.

What Kind of Metals Can Laser Cut?

Carbon Steel

Carbon steel is one of the most common metals cut using a laser because it cuts easily and leaves smooth edges. This type of metal is perfect for parts used in cars and machinery.

Stainless Steel

Stainless steel is also popular. It sometimes needs a more powerful laser, but on the flip side, the result is a surface that is polished and shiny. This finish is excellent when making creations, such as kitchen appliances, artwork, and modern buildings, as it makes them much more durable and visually appealing.

Aluminum

Cutting aluminum is a little harder because it is very reflective. This type of metal bounces the laser light back. However, the special fiber lasers can cut it without much effort. Aluminum is especially useful for crafting airplane parts and large signs among many other things.

Titanium

Another tough metal is titanium. It is immensely durable and does not rust. Laser cutting is ideal for it because it avoids warping or heat damage that can happen when using regular saws.

Brass

Shiny metals, such as brass, can be difficult for the older CO₂ lasers. However, fiber lasers can cut them for its shorter wavelength therefore higher absorb efficiency. These metals are used a lot for custom hardware, decorations, and parts inside electronics.

For the whole supported materials list, check out this page.

How to Get the Best Laser Cutting Result

To ensure a perfect cut with a laser cutter, the operator must understand a few important factors that all work together. These are power, speed, and focus. When using too much power, the edges of the metal can potentially burn. On the other hand, too little power will prevent the laser from cutting all the way through the materials. The trick is to find the right balance of power and speed for the metal's type and how thick it is.

An assist gas is a critical tool that every operator must have in their toolkit to ensure a successful outcome. This is usually oxygen or nitrogen. Or it can be just plain air in some cases. This gas has two main jobs. It blows away the melted metal right after the laser cuts, and it helps cool down the cutting spot. Using the right gas can make the edges look better, stop the metal from rusting quickly, and even make the cutting go faster. Also, the best results come from using metal that is clean and flat, not rusty or dirty. You must also keep the laser machine tuned up and adjusted so that it performs the same every time.

Different Fiber Laser Power and Their Metal Cutting Ability

The power rating of a fiber laser is measured in watts, or 'W'. The more power it has, the thicker and tougher the materials it can slice through and the faster it can do the job.

Tools that run below 100W are considered low power. These are perfect for detailed engraving or cutting thin materials. For example, xTool F2 Ultra – a 60W MOPA laser – can cut metal of around 2mm thickness. They are not strong enough for heavy-duty metal cutting.

Mid-Range power is around 800W to 1200W. These lasers are the reliable workhorses. They are affordable and can easily cut through several millimeters of common metals, such as carbon steel, stainless steel, and aluminum.

High power tools run at 2000W or higher. These are the industrial-strength tools. A 2000W laser can slice through very thick metal, over 10 millimeters of carbon steel and up to 6 millimeters of stainless steel. They are also powerful enough to cut tougher materials, such as copper and brass, though they are only a few millimeters thick. While these cutting tools are faster and much more flexible, they use a lot more electricity and cost more to buy and run.

Metal Laser Cutting Machine vs. Metal Laser Cutting Services

Owning your own laser cutter is much better than paying an outside service to do your cutting. Whether you are making some small batch metal parts or doing prototyping, this gives you much more control and can save you money in the long run. While outsourcing is fine for very large or rare projects, relying on an outside service means you have to wait for their schedule and pay whatever price they set, and this can rob you of flexibility.

When you have a machine in your own shop, you get the freedom to quickly try out new ideas, change your designs instantly, and make products exactly when you need them. This level of control over production speed and quality is a huge benefit for small businesses and serious makers, making it much easier to grow your business or turn your creative metal art and signs into something truly profitable.

What You Can Do with a Metal Laser Cutting Machine

A laser cutter lets you make just about anything that you can imagine. You can design and build a large assortment of custom creations, such as cool jewelry, detailed art for your walls, or even signs for a small business. For people running their own shops, this machine means they can make products right away instead of waiting and paying an outside company.

MetalFab is a great example of this. It provides a handheld laser machine with power choices of 1200W and 800W, as well as an optional CNC cutter to do precise or batch metal work. Someone can even use it to make and weld metal parts from their home, proving you do not need a huge factory to do serious metal fabrication.

Here are some metal projects done with MetalFab: